Method for forming composite components and tool for use therein

ABSTRACT

A method of making an aircraft component is provided, wherein the method comprises the steps of: 
     providing a mould ( 1 ) for the receipt of a material ( 3 ) from which the aircraft component is to be made providing the mould with said material providing an intensification tool ( 14 ) in spaced relationship to the mould and heating the material, tool and mould so that the tool expands and applies pressure to the material and so as to form the component and 
     wherein the linear coefficient of thermal expansion of the tool in a first direction is matched to the coefficient of thermal expansion of the component in the first direction, and the coefficient of thermal expansion of the tool in a second direction is greater than the coefficient of thermal expansion of the component in the second direction, the tool being provided with at least one contacting surface for contacting the material and through which pressure is applied to the material, the expansion of the tool in the second direction causing the at least one contacting surface to contact, and exert pressure on, the material.

This application claims priority to Great Britain Application No.0712535.4, filed 28 June 2007, the entire contents of each of which arehereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a method suitable for forming compositecomponents and a tool for use in such a method. The method may also beused to form other components using a moulding process.

BACKGROUND OF THE INVENTION

Composite components may be manufactured using moulding processes usinga mould to form a component during a forming process, in which heat andpressure are typically applied. The mould provides a surface which formsa component surface having a complementary shape to the mould surface.Intensification tools (“intensifiers”) are sometimes used in carbonfibre reinforced plastic component manufacture. Intensifiers enable thesurface of the component which is not in contact with the mould tool tobe moulded with greater precision. Intensifiers also assist in reducingthe bulk volume of the component during the forming process. Thisdebulking removes air from the material to help avoid undesirable voidsin the final component. The intensifiers typically rely on the thermalexpansion of the intensifier material during the forming process toapply pressure to the component. Therefore, intensifiers are often madefrom materials (such as aluminium) with coefficients of thermalexpansion which are high relative to the coefficients of expansion ofthe component. Alternatively or additionally, an autoclave willtypically be used to apply pressure during the forming process.

It is known to use intensifiers to control internal component dimensionsfor components manufactured using the VAP (Vacuum Assisted Process)system developed by EADS Military Air Systems, Augsburg. The toolingcomprises a mould tool and an intensifier, where the intensifier ismanufactured from a material with a higher coefficient of thermalexpansion than the mould. The VAP process does not rely on an autoclavefor pressure so component consolidation is achieved by allowing theintensifier to expand in all dimensions inside the mould and compressthe component.

It is also known to use intensification tools in a process known as theRTI (Resin Transfer Injection) process. The intensifiers aremanufactured from an airpad bag, which is constructed from carbon fibreand silicone. The carbon fibre helps to retain the tool's shape whilstthe silicone expands to consolidate the component. The intensifierexpands evenly in all directions.

The applicants have recognised that processes using intensifiers with ahigh coefficient of thermal expansion in three dimensions suffer fromproblems when used for long components. For example, as a result of theintensifier having a high thermal expansion coefficient (as is requiredto cause sufficient compression of the component-forming material), theintensifier expands lengthwise by an amount that makes it difficult toform accurately local changes in geometry in the component at thedesired locations in the lengthwise direction.

SUMMARY OF THE INVENTION

The present invention seeks to mitigate one or more of theabove-mentioned problems.

In accordance with a first aspect of the present invention, there isprovided a method of making a composite component, wherein the methodcomprises the steps of:

-   providing a mould for the receipt of a material from which the    component is to be made;-   providing the mould with said material;-   providing an intensification tool in spaced relationship to the    mould; and-   heating the material, tool and mould so that the tool expands and    applies pressure to the material, and so as to form the component;    wherein;-   the linear coefficient of thermal expansion of the tool in a first    direction is matched to the coefficient of thermal expansion of the    component in the first direction, and the coefficient of thermal    expansion of the tool in a second direction is greater than the    coefficient of thermal expansion of the component in the second    direction;-   the tool being provided with at least one contacting surface for    contacting the material and through which pressure is applied to the    material, the expansion of the tool in the second direction causing    the at least one contacting surface to contact, and exert pressure    on, the material.

This first aspect of the present invention may be advantageous whenmaking long components. In this case, the method of the first aspect ofthe present invention facilitates the matching of the lengthwiseexpansion of the intensification tool and the component, thereforeenabling the accurate formation of local changes in geometry in thecomponent at the desired locations in the lengthwise direction.Furthermore, the expansion on heating of the tool in a second direction(typically across the width of the tool) is greater than the expansionon heating of the component, and so the tool exerts a pressure on thematerial in the second direction, thus compressing the material.

The term “matched” indicates that the coefficients of thermal expansionof the tool and component in the first direction are sufficientlysimilar to one another that the difference in length of expansionbetween the tool and component, measured over the length of thecomponent to be formed, when heated to the maximum operating temperatureused in the method is below a pre-determined tolerance. The tolerancewill depend on the specific component being manufactured. The skilledperson will appreciate that the tolerance for a specific component beingmanufactured may readily be determined from the desired geometry of thatcomponent. The tolerance may for example be determined as a function ofthe maximum length between local variations in geometry. A typicaltolerance may, for example, have a maximum value of no more than 5 mm,typically no more than 3 mm and in certain embodiments no more than 2mm.

There now follows a description of optional features concerning themethod of the first aspect of the present invention.

The difference between the coefficient of thermal expansion of the toolin the first direction and the co-efficient of thermal expansion of thecomponent in the first direction is typically no more than 5×10⁻⁶K⁻¹,further typically no more than 2×10⁻⁶K⁻¹ and in certain embodiments nomore than 10⁻⁶K⁻¹.

The coefficient of thermal expansion of the tool in the second directionmay be at least 4 times (typically at least 6 times and in certainembodiments at least 8 times) greater than the coefficient of thermalexpansion of the component in the second direction.

The coefficient of thermal expansion of the tool in the second directionmay be greater than the coefficient of thermal expansion of the tool inthe first direction.

In accordance with a second aspect of the present invention, there isprovided a method of making a composite component, wherein the methodcomprises the steps of:

-   providing a mould for the receipt of a material from which the    component is to be made;-   providing the mould with said material;-   providing an intensification tool in spaced relationship to the    mould; and-   heating the material, tool and mould so that the tool expands and    applies pressure to the material, and so as to form the component;    wherein-   the coefficient of thermal expansion of the tool in a first    direction is less than the coefficient of thermal expansion of the    tool in a second direction;-   the tool being provided with at least one contacting surface for    contacting the material and through which pressure is applied to the    material, the expansion of the tool in the second direction causing    the at least one contacting surface to contact, and exert pressure    on, the material.

The method of the second aspect of the present invention uses a toolwith anisotropic coefficients of expansion. This is typically of usewhen it is desirable to match the coefficient of expansion of the toolwith that of the component in the first direction, but when it isdesirable to exert pressure on the material by having a tool with acoefficient of expansion that is greater than the coefficient ofexpansion of the component in the second direction.

There now follows a description of optional features concerning themethods of both the first and second aspects of the present invention.

The coefficient of thermal expansion of the tool in the second directionmay be at least 10⁻⁵K⁻¹, typically at least 2×10⁻⁵K⁻¹ and in certainembodiments at least 3×10⁻⁵K⁻¹.

The coefficient of thermal expansion of the tool in the first directionmay be no more than 10⁻⁵K⁻¹, typically no more than 5×10⁻⁶K⁻¹ and incertain embodiments no more than 3×10⁻⁶K⁻¹.

The coefficient of thermal expansion of the component in the firstdirection may typically be no more than 10⁻⁵K⁻¹, further typically nomore than 5×10⁻⁶K⁻¹ and in certain embodiments no more than 3×10⁻⁶K⁻¹.

It is appreciated that the material will typically undergo some form oftransformation during the production process, for example, the materialis typically altered by the heating process. The material may comprise aresin-forming precursor which is initially in a liquid form. On heating,the precursor may be transformed into a solid resin. The material maycomprise a reinforcing element (such as carbon fibre) and a precursorwhich, on heating, forms a matrix around the reinforcing element. Theprecursor may, on heating, form a resin. It will be understood from theforegoing that the use of the word “material” is intended to coverstarting product(s) and intermediate product(s). The term “component” isintended to cover the fully cured product(s).

It will be appreciated that the steps of the methods of the first andsecond aspects of the present invention are not necessarily sequentialor distinct. For example, one may inject a part of the material into amould which has already been provided with the tool, the part of thematerial therefore being injected into a cavity between the mould andthe tool. This may occur, for example, during a resin infusion process.Alternatively, the tool may be introduced after the material has beenprovided into the mould. An example of this may be the introduction of aprepreg into the mould.

The coefficient of thermal expansion of the tool in the second directionmay typically be at least 4 times (further typically at least 6 timesand in certain embodiments at least 8 times) greater than thecoefficient of thermal expansion of the tool in the first direction.

The first direction may be substantially transverse to the seconddirection.

The tool may comprise a laminate. The normal to the plies of thelaminate material may be substantially parallel to the second direction.

It is preferred that the component is an elongate component, such as aspar. In this case, it is preferred that the first direction correspondsto the lengthwise direction of the elongate component. The seconddirection may correspond to the width of the elongate component.

The tool may be U-shaped in section, and preferably elongate. The toolmay comprise two flanges interconnected by a web, the web preferablybeing elongate. The first direction may correspond to the lengthwisedirection of the web. The web may typically be substantially planar. Thesecond direction may be substantially orthogonal to the first directionand may be in the plane of the web.

The web may comprise a laminate. The normal to the plies forming thelaminate may not be parallel to the normal of plane of the web. Thenormal to the plies forming the laminate may be substantially parallelto the plane of the web. The normal to the plies forming the laminatemay be substantially parallel to the second direction.

The shape of the tool may correspond to the shape of the component. Forexample, if the component is elongate, it is preferred that the tool iselongate. If the component is U-shaped in cross-section, it is preferredthat the tool may be U-shaped in cross-section. If the component isW-shaped or N-shaped in cross-section, it is preferred that the tool maycorrespondingly be U-shaped or N-shaped in cross-section. A U-shapedcomponent may comprise two component flanges interconnected by acomponent web. The component web may be elongate and may besubstantially planar. The first direction may correspond to the lengthof the component web. The second direction may be in the plane of thecomponent web.

The tool may have a length of at least 5 m, preferably a length of from5 m to 20 m, and more preferably a length of from 6 m to 16 m.

In accordance with a third aspect of the present invention, there isprovided an intensification tool for use in the methods of the first andsecond aspects of the present invention.

In particular, in accordance with a fourth aspect of the presentinvention, there is provided an intensification tool for exertingpressure on a material in a mould, when said material is heated to forma component, wherein:

-   the tool comprises at least one contacting surface for contacting    the material;-   the linear coefficient of thermal expansion of the tool in a first    direction is less than the linear coefficient of thermal expansion    of the tool in a second direction; and-   the tool is arranged such that in use thermal expansion of the tool    in the second direction causes the at least one contacting surface    to contact, and exert pressure on, the material.

Preferably the tool according to embodiments of the fourth aspect ismade from a laminate material and substantially all of the plies of thelaminate are arranged in substantially parallel alignment with the planeof the at least one contacting surface.

The tool of the third aspect of the present invention may comprise thosefeatures of the tool described above in relation to the methods of thefirst and second aspects of the present invention. For example, the toolmay comprise a U-shaped structure, with two flanges interconnected by aweb. The tool may be elongate.

The “first direction” and “second direction” referred to in the methodof the second aspect of the present invention preferably corresponds tothe “first direction” and “second direction” respectively as referred toin the method of the first aspect of the present invention. Likewise,the “first direction” and “second direction” referred to in relation tothe tool of the third aspect of the present invention may preferablycorrespond to the “first direction” and “second direction” respectivelyreferred to in the methods of the first and/or second aspects of thepresent invention.

In accordance with a fifth aspect of the present invention there isprovided an apparatus comprising a tool in accordance with the third orfourth aspects of the present invention and a mould for forming acomposite component.

In accordance with a sixth aspect of the present invention, there isprovided a method of making an intensification tool in accordance withthe third or fourth aspect of the present invention, the tool beingsubstantially U-shaped in cross-section and having two flangesinterconnected by a web, wherein the method comprises the steps of:

-   providing a mould for the formation of the web of the tool    introducing into the mould a plurality of plies of web-forming    material so as to form a stack, the normal to the plies being    non-parallel to the normal to the plane of the web and heating the    stack so as to form the web.

Heating may take place in an autoclave. The web may be machinedpost-heating to achieve a desired shape or finish.

The angle between the normal to the plies and the normal to the web maytypically be at least 80 degrees. The normal to the plies may beorthogonal to the normal to the web. The normal to the plies forming thelaminate may be substantially parallel to the second direction.

The direction of stacking of the plies may correspond to the width of atool with a U-shaped cross-section.

The tool may then be completed by co-curing the web with two sideportions, each side portion comprising a flange.

DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example only withreference to the following Figures of which:

FIG. 1 is a schematic perspective view of a component being formedbetween a mould and an intensification tool, the intensifier tool beinga known tool;

FIG. 2 is a plan view of the mould-tool-component ensemble of FIG. 1;

FIG. 3 is a cross-section through the mould-tool-component ensemble ofFIGS. 1 and 2;

FIG. 4 is a schematic cross-section of a U-shaped carbon-fibre memberhaving a conventional ply lay-up;

FIG. 5 is a schematic cross-section through an intensification tool inaccordance with an embodiment of the present invention; and

FIG. 6 is a schematic cross-section through a pattern tool showing themanufacture of an intensification tool in accordance with an embodimentof the present invention.

DETAILED DESCRIPTION

A known method of making a component is now described with reference toFIGS. 1, 2 and 3. FIGS. 1, 2 and 3 show the spatial relationship betweenan intensification tool (shown generally by reference numeral 4), thematerial 3 from which the component is to be made and a mould (showngenerally by reference numeral 1) that is used to make a component. Theintensification tool 4 is brought into spatial relationship with themould so as to form a cavity into which material 3 may be provided.Material (for example, in the form of reinforcing fibres dispersed in amatrix-forming precursor) is introduced into the cavity.

The material 3 is then heated whilst pressure is applied to the materialby the intensification tool 4 (due to thermal expansion as describedabove). The material is heated until it reaches its desired curetemperature and the material is then held at this temperature for apre-determined period of time (the dwell time) causing the formation ofthe component, heating of the matrix-forming precursor causing theformation of a matrix, the matrix being reinforced by fibres. Thematrix-forming precursor may be a curable resin precursor (for exampleepoxy resin), wherein heating the precursor to the curing temperaturecauses the formation of the resin. The component is formed on curing ofthe precursor. The component takes the shape of the mould at the cure ofthe resin.

The application of pressure by the intensification tool 4 causescompression of the material, thus consolidating (or debulking) thematerial from which the component is formed. Application of pressure bythe intensification tool 4 is able to form a surface of the componenthaving a well-defined geometry. Use of an intensification tool mayreduce the need to machine the component post-heating.

The mould 1 is provided with a U-shaped, component forming surface whichis defined by laminate structure 2. The laminate structure is shown inFIG. 3. The mould is made from a laminate material, for example a carbonfibre reinforced plastic such as LTM211, which has a coefficient ofthermal expansion of 2.5×10⁻⁶K⁻¹ in the plane of the plies and3.1×10⁻⁵K⁻¹ normal to the plane of the plies.

The component is formed form a fibre reinforced composite material, forexample in this embodiment a material from which the component is formedis Hexcel M21E-IMA. The material is deposited in a laminate structure sothat a laminate component is formed. The component has a coefficient ofthermal expansion of 2.8×10⁻⁶K⁻¹ in the plane of the plies and3.2×10⁻⁵K⁻¹ normal to the plane of the plies. The laminate structure ofthe material from which the component is to be made is essentially thesame as the mould in that the plies of the mould and material areessentially parallel to the U-shaped surface of the mould which definesthe shape of the component. The coefficients of thermal expansion of thecomponent are matched to the coefficients of thermal expansion of thelaminate structure 2 of the mould 1. Hence, the component will expand byabout the same amount as the mould in all directions. This means that itis possible to form accurately local changes in geometry in thecomponent at the desired locations in the lengthwise direction. This isimportant in the example given because the mould and component are long,so the effect of any mismatch between the mould and the component inexpansion coefficient will be more pronounced over large distances.

The hatched region in FIG. 3 is used to clearly differentiate thematerial 3 from the mould 1 and tool 4. The hatching does not representthe ply structure within material 3. The laminate structure of material3 is discussed above.

The intensification tool 4 is elongate and substantially U-shaped incross-section with two flanges 5, 6 interconnected by a web 7. The toolis made from a metallic material (such as aluminium) which has a highcoefficient of expansion. The high coefficient of expansion of theintensification tool 4 ensures that flanges 5, 6 are urged into thematerial from which the component is formed and so effectiveconsolidation of the material is achieved. However, the tool expandsmore than desired in a lengthwise direction because of the highcoefficient of expansion of the intensification tool 4.

FIG. 4 shows how the plies of a U-shaped carbon-fibre member, such as anintensification tool, would conventionally be laid-up. Theintensification tool 44 is substantially U-shaped in cross-section withtwo flanges 45, 46 interconnected by a web 47. The planes of the plies(one of which is labelled 48) in the web are substantially parallel tothe surface of the web. The plies in the flanges 45, 46 are parallel tothe internal and external surfaces of the flanges.

The method described above with reference to FIGS. 1, 2 and 3 may beadapted to provide a method in accordance an embodiment of the presentinvention. This may be done by replacing the prior art intensificationtool 4 with an intensification tool in accordance with an embodiment ofthe present invention.

An example of such a tool in accordance with an embodiment of thepresent invention is shown in FIG. 5. The tool 14 is substantiallyU-shaped in cross-section, with two flanges 15, 16 projecting from aninterconnecting web 17. The tool 14 is made from a laminate material.The plies in the flanges 15, 16 are parallel to the internal andexternal surfaces of the flanges. The planes of the plies (one of whichis labelled 18) in the web are substantially normal to the surface ofthe web. The tool 14 is made from cured LTM-211 (Advanced CompositesGroup).

The coefficient of expansion of the tool 14 along the length of the toolis the in-plane coefficient of expansion (2.5×10⁻⁶K⁻¹), which is lowerthan the out of plane coefficient of expansion (3.1×10⁻⁵K⁻¹) Thereforethe coefficient of expansion may be considered to match the coefficientof expansion of the component (2.8×10⁻⁶K⁻¹) in the lengthwise direction.This means that it is possible to form accurately local changes ingeometry in the component at the desired locations in the lengthwisedirection.

A further advantage of the tool is that, the web 17 has its highest (outof plane) coefficient of expansion of the tool oriented in the widthdirection. This means that the coefficient of expansion of the web 17across the width of the tool 14 is the coefficient of expansion normalto the plies i.e. 3.1×10⁻⁵K⁻¹. The coefficient of expansion of thecomponent in the same “width” direction is 2.6×10⁻⁶K⁻¹. Thus, during theheating process, associated with curing the material to form thecomponent, flanges 15, 16 are urged into the corresponding flanges ofthe material, compressing the material and reducing its volume.

Those skilled in the art will realise that in the tools of FIG. 5, thewidth of the flanges relative to the width of the web is relativelysmall and so the contribution that the flanges make to the coefficientof thermal expansion of the tool in a direction corresponding to thewidth of the tool may be negligible.

A method of making a tool in accordance with an embodiment of thepresent invention is now described with reference to FIGS. 5 and 6. Web17 is made by stacking plies 20, 21, 22, 23, 24, 25 of tool-formingmaterial on top of each other in a tool mould 26. The stacking directionof the plies corresponds to the width of the web 17. Once the requirednumber of plies has been reached, the stack is heated in the tool mouldin an autoclave to form the web 17. The web may be machined, ifnecessary. Referring to FIG. 5, web 17 is incorporated into tool 14 asfollows. Web 17 is introduced into a mould (not shown) and side portions19, 20 are formed by laying up plies of material in the mould around theweb 17. The mould is then heated in an autoclave to co-bond the sideportions to the web 17, thus forming a U-shaped tool 14.

Whilst the present invention has been described and illustrated withreference to particular embodiments, it will be appreciated by those ofordinary skill in the art that the invention lends itself to manydifferent variations not specifically illustrated herein.

By way of example, the material from which the component is formed maycomprise a prepreg. In this case, the plies of prepreg material areplaced onto the mould to the desired thickness and the intensificationtool brought into spaced relationship with the mould once the plies ofprepreg have been laid down.

Alternatively, plies of reinforcement members may be placed onto themould to the desired thickness and the intensification tool brought intospaced relationship with the mould once the plies of reinforcementmembers have been laid down. Matrix-forming precursor may then beintroduced around the reinforcement members.

In yet another embodiment of the invention, the method of producing acomponent may use a tool with a substantially isotropic the tool is madefrom a laminate material and substantially all of the plies of thelaminate substantially parallel alignment with the plane of at least onecontacting surface, if this coefficient of expansion is matched to thecoefficient of expansion of the component in a first direction and ifthe coefficient of thermal expansion of the tool is greater than thecoefficient of expansion of the component in a second direction.

In yet another embodiment of the invention, the web of FIGS. 5 and 6 maybe bonded onto side portions which have already been cured, as opposedto being co-bonded with the side portions. Cured side portions may bemechanically fastened to the web.

It will be clear to those skilled in the art that an intensificationtool in accordance with an embodiment of the present invention need notbe U-shaped.

In the tool of FIG. 5, substantially all of the plies of the laminate(in both the flanges and the web) are arranged in substantially parallelalignment with the plane of the contacting surfaces of the flanges.Accordingly the coefficient of thermal expansion in the normal directionto the contacting surface is dominated by (and may substantiallycorresponds to) the coefficient of thermal expansion out-of-plane, orcross-ply, direction (which as described above is greater than in thein-plane, or through-ply, direction). This ply orientation helps toensure that the plane of greatest expansion of the tool is generallyaligned with the pressure force that will be applied to the material.Those skilled in the art will appreciate that such an arrangement ofplies may be readily applied to any shape of intensification tool.

Of course, features described with reference to one particularembodiment of the invention may be equally applicable to otherembodiments on the invention.

Those skilled in the art will realise that the plying shown in theFigures may be indicative of the orientation of the plies, and is notindicative of the thickness of the plies. Each ply is, in reality,thinner than indicated in the Figures.

It will be appreciated by those skilled in the art that the embodimentsof the invention may be particularly suitable for manufacturing aircraftcomponents. For example, aircraft components may require relativelycomplex geometries. Additionally or alternatively, aircraft componentsmay require relatively large single piece components to be manufactured.It will also be appreciated that aircraft composite components often usehigh temperature resin systems and that the higher the temperature atwhich the component is formed the more significant the effects ofthermal expansion. It is also generally of increased importance toensure that aircraft components are debulked and free of voids.

Where in the foregoing description, integers or elements are mentionedwhich have known, obvious or foreseeable equivalents, then suchequivalents are herein incorporated as if individually set forth.Reference should be made to the claims for determining the true scope ofthe present invention, which should be construed so as to encompass anysuch equivalents. It will also be appreciated by the reader thatintegers or features of the invention that are described as preferable,advantageous, convenient or the like are optional and do not limit thescope of the independent claims.

1. A method of making a composite component, wherein the methodcomprises the steps of: providing a mould for the receipt of a materialfrom which the component is to be made; providing the mould with saidmaterial; providing an intensification tool in spaced relationship tothe mould; and heating the material, tool and mould so that the toolexpands and applies pressure to the material, and so as to form thecomponent, wherein the linear coefficient of thermal expansion of thetool in a first direction is matched to the coefficient of thermalexpansion of the component in the first direction, the coefficient ofthermal expansion of the tool in a second direction is greater than thecoefficient of thermal expansion of the component in the seconddirection, and the tool being provided with at least one contactingsurface for contacting the material and through which pressure isapplied to the material, the expansion of the tool in the seconddirection causing the at least one contacting surface to contact, andexert pressure on, the material.
 2. A method according to claim 1wherein the difference between the coefficient of thermal expansion ofthe tool in the first direction and the co-efficient of thermalexpansion of the component in the first direction is no more than5×10⁻⁶K⁻¹.
 3. A method according to claim 2 wherein the differencebetween the coefficient of thermal expansion of the tool in the firstdirection and the co-efficient of thermal expansion of the component inthe first direction is no more than 10⁻⁶K⁻¹.
 4. A method according toclaim 1 wherein the coefficient of thermal expansion of the tool in thesecond direction is at least 4 times greater than the coefficient ofthermal expansion of the component in the second direction.
 5. A methodaccording to claim 4 wherein the coefficient of thermal expansion of thetool in the second direction is at least 8 times greater than thecoefficient of thermal expansion of the component in the seconddirection.
 6. A method according to claim 1 wherein the coefficient ofthermal expansion of the tool in the second direction is greater thanthe coefficient of thermal expansion of the tool in the first direction.7. A method according to claim 1 wherein the coefficient of thermalexpansion of the tool in the second direction is at least 2×10⁻⁵K⁻¹. 8.A method according to claim 1 wherein the coefficient of thermalexpansion of the tool in the first direction is no more than 5×10⁻⁶K⁻¹.9. A method according to claim 1 wherein the coefficient of thermalexpansion of the component in the first direction is no more than5×10⁻⁶K−1.
 10. A method according to claim 1 wherein the coefficient ofthermal expansion of the tool in the second direction is at least 4times greater than the coefficient of thermal expansion of the tool inthe first direction.
 11. A method according to claim 1 wherein the firstdirection is substantially transverse to the second direction.
 12. Amethod according to claim 1 wherein the tool comprises a laminatematerial with plies in a plane and a normal to the plies of the laminatematerial are substantially parallel to the second direction.
 13. Amethod according to claim 1 for the manufacture of an elongatecomponent, wherein the first direction corresponds to the lengthwisedirection of the elongate component.
 14. A method according to claim 13wherein the second direction corresponds to the width of the elongatecomponent.
 15. A method according to claim 1 wherein the tool isU-shaped in cross-section and is elongate.
 16. A method according toclaim 15 wherein the tool comprises two or more flanges interconnectedby an elongate web.
 17. A method according to claim 16, wherein the toolcomprises two flanges and wherein the web is planar, the first directioncorresponding to the lengthwise direction of the web and the seconddirection being substantially orthogonal to the first direction and inthe plane of the web.
 18. A method according to claim 17 wherein the webmay comprise a laminate with plies in a plane and a normal to the pliesforming the laminate are not parallel to the normal of the plane of theweb.
 19. A method according to claim 18 wherein the normal to the pliesforming the laminate is substantially parallel to the second direction.20. A method according to claim 1 wherein the shape of the toolcorresponds to the shape of the component.
 21. A method according toclaim 20 wherein the tool is elongate and U-shaped, W-shaped or N-shapedin cross-section, and the component is elongate and the cross-sectionalshape of the component corresponds to the cross-sectional shape of thetool, the component comprising two or more component flangesinterconnected by a component web.
 22. A method according to claim 1wherein the tool has a length of at least 5 m.